Heat reactive plastic



or mixtures of this substance with some Patented May 5, 1925.

UNITED STATES CARLETdN ELLIS, OF MONTCLAIR, NEW JERSEY.

HEAT anaerrvn rnns'rrc.

No Drawing.

To all whom it may concern:

lie it known that I, OARLETON ELLIS, a citizen of the United States, and a resident of Montclair, in the county of Essex and State .of New Jersey, have invented certain new and useful Improvements in Heat Reactive Plastics, of which the following is a specification;

This invention relates to synthetic plastic materials and molding compounds made therefrom and to the rocess of making such products, the basis of which being methylol urea or its appropriate derivatives. These may be used alone or preferably with vafious naturalor synthetic resins or resinforming substances,with or without fillers or extending and coloring agents. T Either the monomethylol urea or the dimethylol urea may be used sin ly or in admixture or their appropriate erivatives be may be utilized, e. g., substituted ureas acting in a similar or equivalent manner. The

1 term 'urca is employed here to embrace carbamide and appropriate derivatives.

' In the present invention dimethylol urea monomethiylol .urea are preferred. When dimethylo urea is .heated it melts some where in the neighborhood of 120- C. but on further heatingfor example 20 or degrees higher reaction takes tion occurs. 1 For example it may heated nearly 100 dcgrees'abovc its hardening point before it begins to show signs of decompo sition.- The proper of heat-setting or becoming thermo-rigi ing compounds which under heat and. prossure become solidified or consolidated to a shaped mass. Thus molded articles may .molding press while stillhot'an'd be hanrequired to cool f'thg moldy-in the died and exposed-without deformation or; {The labor cost in loss of surface lust m'olding is so great; at the few resents a considerable item in of manufacture. Hence the desirabilit of.

wholly infusib 1000 pounds and higher.

lace. and a susbtance is formed which is quite infusible' reduced makes possible the. use of the material in ones a basis of mold- Application filed June 14, 1922. Serial No. 568,251.

duction of plastics from fusible resins which do not harden .or become thermo-rigid repthe total cost a resin not necessarily infusible but w ich will sufiiciently harden in the mold at the molding tem erature. y Dimethylo urea is suitable for this purpose ,on account of its hardening property, the differential or spreadin tem erature between the melting point and tie point at which it decomposes under strong heating is sufliclently rest that even though not e it is capable of meeting the demand for a labor-saving molding compound of this general character. i

It is not necessary to employ pure dimethylol urea but the crude substance, contaminated with various other bodies, may used in many cases. It is however sirable to heat the crude dimethylol ureafor a period to thorou hly dry it and remove as far as possi' 1e any substances which might evolve gases in the mold. Thus dimethylol urea was baked 18 hours at 120 C. it Whats product was obtained which was placed in a mold in powdered form and molded at 300 F. under, a. pressure of A white solid article was obtained'which had 'a glossy surface and which when placed in a Bun sen flame 'did" not melt but burned slowly.

with carbonization.

Desirable combinations maybe made.

with various synthetic resins as for example b incorporation with a fusible phenol forma'ldehyde resin. Such a mixture on heating in the mold yields a. heat-resistingurea compound. A product of this character will set sufliciently in hot pressing to be useful in molding operations. The reaction 1s a complex one, the urea compound probably forming the substance In .partand also probably reactmg with the phenol formaldehyde tain extent. In place 0 naphthol and other reactive bodies are not excluded. Acetaldehyde also may benised roduct to a' cerwith, orin substitution for," formaldehyde.-

,phenfol, fcresol,

exampleis' the following. ,210 parts by weight of phenol and 150 arts of aqueous formaldehyde were-place in anautoclave and heated for, 2 hours'raising the pressure as quickly as possible to 100 pounds. and maintaining this ressure during the reaction. This called or a temperature of III i 138 to 143 'plete the water which had' separated from that had formed was re-' r: perat res phenol or cresol, an excess of the phenolic amount of phenol is about 80 C.

corporated with 10 parts phenol formaldehyde resin and onheating slightly to complexes furfural the substance. obtained is w C. After the reaction was comthe resinous mass moved. The dry resin was fusible and was completely soluble in alcohol. weight of well dried dimethylol urea was inby weight of this was found to set to a product of substantially higher meltingpoinhthan the original IIllX.

On adding larger proportions of the dimethylol urea up to approximately an equal weight a the fusible phenolformaldehyde resin rious modified complex substances could e obtained on hot pressing at tembetween 125 and 150 C. These ranged from ones which on hot increased in melting point only I which had a very dccided increment in melting point. Another type of molding com osition is made from a binder comprising imethylol urea and a resin obtained by reacting'with furfural on phenol. For example furfural is mixed with'several times its volume of produ ts pressin body being used and this is treated with a small amount of hydrochloric acid. The

be required solely steam distillation or in any other suitable manner permits of the formation ofa ,fusible furfural resm which is then capable'of being 'incorpprated with fillers or extending agents. he amount of hydrochloric acid used need not be large preferably when kept down to a few per centthere is'lessxdanger of forn ing an infusible product. The reacti'onmay be allowedjo take place advantageously at A fusible resin having been obtained in this manner may be incorporated with dimethylol urea in various pro ortions. Thus a major proportion of the u-rfural resinvimay be used in'some cases while inothers it is desirable to use an ex- 'cess of the dimethylol urea. As the plastic darkened by the furfural resin the composition is best .ada ted foruse in making, brown or black mo din 'compounds.- I v t 4 L may bea'dded that furfural resin'made as above with an-exoess of phenol may also be incorporatedwith other substances as for erty of hardening when 1 part by rial is infusible it cannot be used a advantage.

' actin hydrochloride is dissolved m 2 may be removed at ample equal parts treated with 2 .to 2 A partsof example paraform or 'hexamethylenetetra-mf ine. Such compositions have the propheated and they may if desired be incorporated with dimethylol urea in any proportions desired.

A suitable composition is made from fusible furfural phenol resin and dimethylol urea in the proportions of 3 parts'of the former toll part of the .latter.- In this case no hexamethylenetetrami'ne'or formaldehyde derivative of such a character is introduced. 4 2 parts of the furfural vphenol resin to' 1 part of .dimethylol urea may likewise be intimately mixed and if desired-10 per cent of liex-amet-hylenetetramine 'may be added.

Preferably however as indicated no hexamethylenet etramine or similar substance is em loyed.. 4 I

' t is a distinct advantage in the recovery of the molding material to. have a resin or binder which does not become entirely infus ible. In molding there is a considerable amount of wastage and if this waste mateairi to. On the other hand if sti l fusi-- ble even though at a higher temperature than that used in molding it is possible to utilize it by suitably fluxing it. A resinous composition which is capable of recovery in this manner therefore forms a part of the present invention.

- Another composition is that made by rep on furfural with aniline hydrochloride. For example 1 part of aniline parts of furfu'ral and is very gently heated and incororated with dimethylol urea.- Care should e taken to avoid any increase of thetem perature which forms an infusible compound prematurely. -Anothercomposition is that involvin a mixture of dimethylol urea and monomet y-'- 101 urea incorporated in :various' proportions as for exampleiequal par-ts by weight; this material may be used byitself for molding pur oses it may also be admixed with the fusl le phenol formaldehyde resin for example as above describedor with a furfural phenol resin or resin. The proportions or ing more of one constituent-thanthefother;

a furf al' aniline used being for ex- -Whilecompositionscontain- I Dime'thylol urea also may be incorporated with phenol'sulphur resins made by, mg on phenol with 'sul'phurchloride. For example 1 part by weight of phenol is sulphur ino'nochloride to yield -a resin as described in my prior application pending.- V r This resin may-be incorporated with 10 pencentiand upwards of'dimethylol urea. l Dimethylol urea also'may be incorporated with a' resin obtained by reacting on acetone or other tketone with formaldehyde as; de-

scribed in my prior applieationspending.

Iii)

may be made by mixing such tillers as for example equal parts of filler and binder to form molding powders.

The filler may be simply ground with the hinder or may be impregnated by means of a solution. Or the materials may be incorporated and Worked out into sheeted form. This may be accomplished by mixing on difi'erential rolls and then running through sheeting rolls.

Paper or cloth may be impregnated and sheets pressed together to form blocks. The binding agent in the form of a solution may be used as a lacquer or incorporated with tiller may be employed as a cement.

. Shaped articles made under heat and pressure in accordance with the foregoing may be defined or characterized by containing a heat-set urea derivative.

\Vhat'I claim is 1. A molding composition containin dimethylol urea and a phenol formaldehyde fusible resin. v

2. A shaped article containing a heat-set methylol urea derivative.

3. A shaped article containing a heat-rust dimethylol urea derivative.

4. The process of making'a binding agent adapted for use in making molding compounds which compriscs incorporating dimethylol urea with a synthetic resin.

5. A shaped article containing a heat-set methylol urea derivative incorporated with Y a synthetic resin.

6. A molding composition containing dimethylol urea.

7. A molding composition containing thoroughly dried dimethylol urea. 8. A molding composition containing a mixture of mono and dimethylol urea.

9. 1 product obtained by heating a methylol urea at or above its melting point until it becomes infusiblc at the temperature of heating.

10. A product obtainer by heating dimethylol urea at or above its melting point until it becomes infusible at the temperature of heating.

11. A molding composition containing a heat treated methylol urea.

12. A molding composition containing a heat treated dimethylol urea.

13. A molding composition containing a heat treated dimethylol urea in powdered form.

14. A molding composition containing methylol urea and a phenolic resin.

15. A molding composition containing methylol urea and an aldehydic resin.

16. A molding composition containing methylol urea and a phenol aldehyde fusible resin.

'17. A resinous composition adapted for moldin containing a methylol urea resin which (Toes not become infusiblc upon mold- 11'1".

18. A molded methylol urea derivative.

CARLETON ELLIS.

iii)

-' of filler and binder to form molding powders.

The filler maybe simply ground with the hinder or may be impregnated by means of a solution. Or the materials may be incorporated and worked out into sheeted form. This may be accomplished by mixing on differential rolls and then running through sheeting rolls.

Paper or cloth may be impregnated and sheets pressed together to form blocks. The binding agent in the form of a solution may be used as a lacquer or incorporated with filler may be employed as a cement. Shaped articles made under heat and pressure in accordance with the foregoing may be defined or characterized by containing a. heat-set urea derivative.

VVhat'I claiin is 1. A molding composition containing dimethylol urea and a phenol formaldehyde fusible resin. I

2. A shaped article containing a heat-set methylol urea derivative.

3. A shaped article containing a heatmet diniethylol urea derivative.

4. The process of making a binding agent adapted for use in making molding compounds which comprises incorporating dimethylol urea with, a synthetic resin.

5. A shaped article containing a heat-set methylol urea derivative incorporated with K a synthetic resin.

6. A molding composition containing dnnethylol urea.

7. A molding composition containing thoroughly dried dimcthylol urea.

8. A. molding composition containing a mixture of mono and dimethylol urea.

9. A product obtained by heating a methylol urea at or above its melting point until it becomes infusiblc at the temperature of heating.

10. A product obtainer by heating dimethylol urea at or above its melting point until it becomes infusible at the temperature of heating.

11. A molding composition heat treated methylol urea.

12. A molding composition heat treated dimethylol urea.

13. A molding composition heat treated dimethylol urea form.

14. A molding composition containing. methylol urea and a phenolic resin.

containing a containing a containing a 1n powdered 15. A molding composition containing methylol urea and an aldehydic resin.

16. A molding composition containing methylol urea and a phenol aldehyde fusible resin.

17. A. resinous composition adapted for molding containing a methylol urea resin \vhich does not become infusible upon moldin".

lS. A molded lnethylol urea derivative.

CARLETON ELLIS.

DISCLAIMER 1,536,881.0arleton; Ellis, Montclair, N. J. HEAT REACTIVE PLASTIC.

' Disclaimer filed dated May 5, 1925; Foster Company v c a Hereby disclaims the article or exec t when such article or product molding [Oficial Gazette April 12, 1932.]

Patent l t larch 16, 1932, by the assignee, Ellisproduct set forth in claims 2, 3, 9, 10, and 18,

as been molded und h composltion that 1s substantially dry. eat and pressure from a DISCLAIMER 1,536,881.C'arleton Ellis, Montclair, N. J. HEAT REACTIVE PLASTIC. Patent dated May 5, 1925. Disclaimer filed March 16, 1932, by the assignee, Ellis- Foster Company. Z

Hereby disclaims the article or roduct set forth in claims 2, 3, 9, 10, and 18, except when such article or product as been molded under heat and pressure from a molding composition that is substantially dry.

[Qflicial Gazette April 12, 1932.] 

